Single-layer integral welding clamp for motor flat wire welding

Abstract

A single-layer integral welding clamp for motor flat wire welding comprises a base, an outer rotating groove disc is arranged on the base, an inner rotating groove disc is arranged in the outer rotating groove disc, a cutter cage disc is arranged between the outer rotating groove disc and the inner rotating groove disc, and the outer rotating groove disc and the inner rotating groove disc are respectively connected with a rotating driving mechanism. A plurality of first inclined grooves are evenly distributed in the outer rotating groove disc in the circumferential direction, a first pin is arranged in each first inclined groove, and each first pin is connected with an outer inserting piece. The utility model relates to a single-layer integral welding fixture for hairpin welding of a flat wire motor, which is characterized in that a single-layer design is adopted, and a ratchet mechanism is adopted to drive a rotating groove disc, so that an inner insertion sheet and an outer insertion sheet are tightly propped against the end part of a copper wire. The scheme is suitable for a four-layer winding stator product with dense wire pins and small slot spacing, all groups of copper wires can be clamped at one time, and quick disassembly and assembly can be realized, so that the first-pass yield and the welding efficiency of hairpin welding of a four-layer winding flat wire motor are improved.

Description

Technical Field

[0001] The utility model relates to the field of machinery, in particular to a welding tool, in particular to a single-layer integral welding fixture for welding motor flat wires. Background Art

[0002] In recent years, the demand for drive motors in the domestic and international new energy vehicle markets has gradually developed towards high power density, high efficiency, high speed and platformization. Flat wire winding motors, with their obvious advantages in efficiency, heat dissipation and performance, have gradually replaced round wire winding motors and become the development trend of new energy vehicle drive motors.

[0003] Currently, 48-slot, 54-slot, 72-slot, and 96-slot designs are popular in the automotive motor industry. Generally, all other factors being equal, a motor with more slots will have better back EMF, torque ripple, eddy current losses, and vibration noise. However, a larger number of slots presents greater challenges in overall welding fixture design.

[0004] The densely packed legs and small slot spacing of multi-slot stators make installation difficult with existing "upper and lower layer rotary clamping" integrated welding fixtures. Currently, a single-point, multiple-clamping method is often used. This results in inconsistent welding conditions each time, leading to inconsistent welding results and a low first-pass weld pass rate. In terms of welding efficiency, the high number of clamping cycles slows production cycles and reduces welding equipment utilization. Summary of the Invention

[0005] The purpose of the utility model is to provide a single-layer integral welding fixture for welding motor flat wires, which is intended to solve the technical problems of poor clamping effect and low welding efficiency of welding fixtures in the prior art.

[0006] The utility model discloses a single-layer integral welding fixture for welding motor flat wires, comprising a base, an outer rotating groove disk is provided on the base, an inner rotating groove disk is provided in the outer rotating groove disk, a knife cage disk is provided between the outer rotating groove disk and the inner rotating groove disk, the outer rotating groove disk and the inner rotating groove disk are respectively connected to a rotating drive mechanism, a plurality of first inclined grooves are uniformly distributed along the circumferential direction on the outer rotating groove disk, a first pin is provided in any first inclined groove, and an outer insert is respectively connected to any first pin, a plurality of second inclined grooves are uniformly distributed along the circumferential direction on the inner rotating groove disk, a second pin is provided in any second inclined groove, and an inner insert is respectively connected to any second pin, a support ring is provided on the knife cage disk, a plurality of first positioning grooves are uniformly distributed along the circumferential direction on the outer side of the support ring on the knife cage disk, and a plurality of second positioning grooves are uniformly distributed along the circumferential direction on the inner side of the support ring on the knife cage disk.

[0007] Furthermore, the rotation drive mechanism connected to the outer rotating groove disk includes a first gear and a second gear. The first gear is arranged on the outer circumferential surface of the outer rotating groove disk, the second gear is engaged with the first gear, and the second gear is provided with a first locking mechanism.

[0008] Furthermore, the first locking mechanism includes a first ratchet wheel arranged on the second gear, a first pawl and a second pawl cooperating with the first ratchet wheel are arranged on one side of the first ratchet wheel, a first pawl conversion mechanism is arranged between the first pawl and the second pawl, and a first driving block is arranged on the first ratchet wheel.

[0009] Alternatively, the rotating drive mechanism connected to the outer rotating groove disk includes a first gear, a second gear and a worm mechanism, the first gear is arranged on the outer circumferential surface of the outer rotating groove disk, the second gear is engaged with the first gear, the worm mechanism includes a vortex rotating shaft, the vortex rotating shaft is arranged in the second gear and cooperates with the second gear through a vortex hole, and a first driving block is provided at the upper end of the vortex rotating shaft.

[0010] Furthermore, the rotation drive mechanism connected to the inner rotating groove disk includes a third gear and a fourth gear. The third gear is arranged on the inner circumferential surface of the inner rotating groove disk. The fourth gear is engaged with the third gear. The fourth gear is provided with a second locking mechanism.

[0011] Furthermore, the second locking mechanism includes a second ratchet wheel arranged on the fourth gear, a third pawl and a fourth pawl cooperating with the second ratchet wheel are arranged on one side of the second ratchet wheel, a second pawl conversion mechanism is arranged between the third pawl and the fourth pawl, and a second driving block is arranged on the second ratchet wheel.

[0012] Furthermore, an outer cover plate and an inner cover plate are provided on the base, and handles are provided on both sides of the base.

[0013] Furthermore, the first positioning groove and the second positioning groove are respectively provided with inner positioning protrusions and outer positioning protrusions, and the first positioning groove and the second positioning groove of the tool cage disc are staggered.

[0014] Compared with existing technologies, this utility model offers significant and effective results. This single-layer, integrated welding fixture is used for hairpin welding of flat-wire motors. It features a single-layer design and a ratchet mechanism that drives a rotating slotted disc, tightening the inner and outer tabs against the ends of the copper wires. This solution is suitable for four-layer stator windings with densely packed wire legs and small slot spacing. It can clamp all copper wires simultaneously and allows for quick assembly and disassembly, thereby improving the first-pass pass rate and welding efficiency for hairpin welding of four-layer flat-wire motors. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a schematic diagram of a single-layer integral welding fixture for welding motor flat wires according to the present invention.

[0016] Figure 2 The utility model is a schematic diagram of the internal structure of a single-layer integral welding fixture for welding motor flat wires.

[0017] Figure 3 This is a schematic diagram of a rotary drive mechanism in a single-layer integral welding fixture for welding motor flat wires according to the present invention.

[0018] Figure 4 The utility model is a schematic diagram of copper wire clamping of a single-layer integral welding fixture for welding motor flat wires.

[0019] Figure 5 The utility model is a schematic diagram of a worm mechanism of a single-layer integral welding fixture for welding motor flat wires.

[0020] Figure 6 It is a schematic diagram of a single-slot structure tool cage disc in the prior art.

[0021] Figure 7 The utility model is a schematic diagram of a knife cage disc in a single-layer integral welding fixture for welding motor flat wires. DETAILED DESCRIPTION

[0022] The following is a further description of the present invention in conjunction with an embodiment. However, the present invention is not limited to the embodiment. All similar structures and similar variations of the present invention should be included in the scope of protection of the present invention. The use of directions such as up, down, front, back, left, and right in the present invention is only for the convenience of clear description and does not limit the technical solution of the present invention.

[0023] like Figure 1-Figure 7 As shown, the utility model is a single-layer integral welding fixture for welding motor flat wires, including a base, an outer rotating slotted disc 1 is provided on the base, an inner rotating slotted disc 3 is provided in the outer rotating slotted disc 1, a knife cage disc 2 is provided between the outer rotating slotted disc 1 and the inner rotating slotted disc 3, the outer rotating slotted disc 1 and the inner rotating slotted disc 3 are each connected to a rotation drive mechanism, a plurality of first inclined slots 4 are uniformly distributed along the circumferential direction on the outer rotating slotted disc 1, any one of the first inclined slots 4 is provided with a first pin 5, and any one of the first inclined slots 4 is provided with a first pin 5. Each pin 5 is connected to an outer insert 6, and a plurality of second inclined grooves are evenly distributed along the circumferential direction on the inner rotating groove disk 3. A second pin is provided in any second inclined groove, and any second pin is connected to an inner insert 9. A support ring 10 is provided on the knife cage disk 2, and a plurality of first positioning grooves 11 are evenly distributed on the outer side of the support ring 10 along the circumferential direction on the knife cage disk 2, and a plurality of second positioning grooves 12 are evenly distributed on the inner side of the support ring 10 along the circumferential direction on the knife cage disk 2.

[0024] Furthermore, the rotation drive mechanism connected to the outer rotating groove disk 1 includes a first gear 13 and a second gear 14. The first gear 13 is arranged on the outer circumference of the outer rotating groove disk 1, and the second gear 14 is engaged with the first gear 13. The second gear 14 is provided with a first locking mechanism.

[0025] Furthermore, the first locking mechanism includes a first ratchet 15 arranged on the second gear 14, and a first pawl 16 and a second pawl 17 that cooperate with the first ratchet 15 are provided on one side of the first ratchet 15, a first pawl conversion mechanism 18 is provided between the first pawl 16 and the second pawl 17, and a first driving block 19 is provided on the first ratchet 15.

[0026] Alternatively, the rotating drive mechanism connected to the outer rotating groove disk 1 includes a first gear 13, a second gear 14 and a worm mechanism, the first gear 13 is arranged on the outer circumferential surface of the outer rotating groove disk 1, the second gear 14 is engaged with the first gear 13, and the worm mechanism includes a vortex rotating shaft 20, the vortex rotating shaft 20 is arranged in the second gear 14 and cooperates with the second gear 14 through a vortex hole, and a first driving block 19 is provided at the upper end of the vortex rotating shaft 20.

[0027] Furthermore, the rotation drive mechanism connected to the inner rotating groove disk 3 includes a third gear 21 and a fourth gear 22. The third gear 21 is arranged on the inner circumference of the inner rotating groove disk 3. The fourth gear 22 is engaged with the third gear 21. The fourth gear 22 is provided with a second locking mechanism.

[0028] Furthermore, the second locking mechanism includes a second ratchet wheel arranged on the fourth gear 22, a third pawl and a fourth pawl cooperating with the second ratchet wheel are arranged on one side of the second ratchet wheel, a second pawl conversion mechanism is arranged between the third pawl and the fourth pawl, and a second driving block 23 is arranged on the second ratchet wheel.

[0029] Furthermore, an outer cover plate 24 and an inner cover plate 25 are provided on the base, and handles 26 are provided on both sides of the base.

[0030] Furthermore, an inner positioning protrusion 28 and an outer positioning protrusion 29 are respectively provided inside and outside the first positioning groove 11 and the second positioning groove 12 , and the first positioning groove 11 and the second positioning groove 12 of the tool cage disc 2 are staggered.

[0031] Figure 6 The tool cage disc is a single-slot structure in the prior art, that is, each slot 30 corresponds to a group of copper wires. However, in the actual motor stator manufacturing process, due to the influence of the previous head twisting process, the actual copper wire position is somewhat misaligned compared with the theoretical digital model. In order to accommodate the copper wire misalignment and facilitate the insertion of the fixture, the two adjacent slots are punched through to increase the width, such as Figure 7 The rear notch is penetrated to retain the inner and outer protrusions to ensure that each group of copper wires is positioned correctly after clamping.

[0032] Specifically, the ratchet, pawl, pawl conversion mechanism, worm mechanism, vortex rotating shaft 20, vortex hole, etc. in this embodiment all adopt well-known solutions in the prior art, which are well understood by those skilled in the art and will not be described in detail here.

[0033] The working principle of this embodiment is as follows:

[0034] This fixture is suitable for stator products with 4-layer windings, and is compatible with products such as 4-layer 48-slot, 4-layer 54-slot, 4-layer 72-slot, and 4-layer 96-slot. This embodiment uses a 4-layer 96-slot stator product as an example.

[0035] Using manual clamping, after the head trimming process, the welding fixture is placed on the copper wire at the stator welding end. The first pawl conversion mechanism 18 is moved to a state where the first pawl 16 contacts the first ratchet 15, preventing the first ratchet 15 from rotating counterclockwise to ensure clamping without loosening. An electric torque gun is used to rotate the first drive block 19 clockwise, driving the outer rotating grooved disc 1 counterclockwise via the first ratchet 15, second gear 14, and first gear 13. This, in turn, drives the outer insert 6 radially inward via the first pin 5 and first bevel 4, pressing the copper wire 27 against the support ring 10 of the knife cage disc 2, thereby clamping the copper wire end. After processing is completed, the first pawl conversion mechanism 18 is moved to a state where the second pawl 17 contacts the first ratchet 15. An electric torque gun is used to rotate the first drive block 19 counterclockwise to drive the outer rotating grooved disc 1 clockwise, driving the outer insert 6 radially outward, thereby loosening the copper wire end. The action process of the inner rotating groove disc 3 and the inner inserting piece 9 is the same as that of the outer rotating groove disc 1.

[0036] There are 24 outer blades 6 and 24 inner blades 9, each capable of covering four groups of copper wires, for a total of 96 groups of copper wires, ensuring no gaps between each group of wires and ensuring excellent clamping. When the outer blades 6 and inner blades 9 are extended, the first and second positioning slots 11 and 12 of the cutter cage disc 2 are significantly larger than the copper wires, facilitating easy entry of the wires.

[0037] The rotary drive mechanism can also adopt a worm mechanism. The advantage is that the vortex rotating shaft 20 drives the gear steplessly through the vortex hole, ensuring more continuous and detailed rotation of the rotating groove disk, thereby ensuring that the insert effectively clamps the copper wire. The specific implementation form is that the electric torque gun rotates the vortex rotating shaft 20. The vortex hole of the vortex rotating shaft 20 drives the second gear 14 to rotate through the pin. The second gear 14 drives the outer rotating groove disk 1 to rotate through the first gear 13, thereby driving the outer insert 6 and the support ring 10 to clamp the end of the copper wire.

[0038] This utility model is a single-layer, integrated welding fixture for hairpin welding of flat-wire motors. It features a single-layer design and a ratchet mechanism that drives a rotating slotted disc, tightening the inner and outer tabs against the ends of the copper wire. This solution is suitable for four-layer stator windings with densely packed wire legs and small slot spacing. It can clamp all groups of copper wire at once and allows for quick assembly and disassembly, thereby improving the first-pass pass rate and welding efficiency for hairpin welding of four-layer flat-wire motors.

[0039] This new design allows for quick assembly and disassembly of the entire fixture. The fixture incorporates two rotary drive mechanisms, one for the inner ring and one for the outer ring, ensuring effective clamping. During assembly, the clamps are tightened manually using an electric torque gun. After welding, the clamps can be removed by manually loosening them with the electric torque gun.

Claims

1. A single-layer integral welding fixture for welding motor flat wires, characterized by: The cam is provided with a plurality of first and second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of second cams, each of which is provided with a plurality of 2. The single-layer integral welding fixture for welding motor flat wires according to claim 1, characterized in that: The rotation drive mechanism connected to the outer rotating groove disk includes a first gear and a second gear. The first gear is arranged on the outer circumference of the outer rotating groove disk. The second gear is meshed with the first gear. The second gear is provided with a first locking mechanism.

3. The single-layer integral welding fixture for welding motor flat wires according to claim 2, characterized in that: The first locking mechanism includes a first ratchet wheel arranged on the second gear, a first pawl and a second pawl cooperating with the first ratchet wheel are arranged on one side of the first ratchet wheel, a first pawl conversion mechanism is arranged between the first pawl and the second pawl, and a first driving block is arranged on the first ratchet wheel.

4. The single-layer integral welding fixture for welding motor flat wires according to claim 1, characterized in that: The rotating drive mechanism connected to the outer rotating groove disk includes a first gear, a second gear and a worm mechanism. The first gear is arranged on the outer circumferential surface of the outer rotating groove disk, and the second gear is meshed with the first gear. The worm mechanism includes a vortex rotating shaft, which is arranged in the second gear and cooperates with the second gear through a vortex hole. A first driving block is provided at the upper end of the vortex rotating shaft.

5. The single-layer integral welding fixture for welding motor flat wires according to claim 1, characterized in that: The rotation drive mechanism connected to the inner rotating groove disk includes a third gear and a fourth gear. The third gear is arranged on the inner circumference of the inner rotating groove disk. The fourth gear is meshed with the third gear. The fourth gear is provided with a second locking mechanism.

6. The single-layer integral welding fixture for welding motor flat wires according to claim 5, characterized in that: The second locking mechanism includes a second ratchet wheel arranged on the fourth gear, a third pawl and a fourth pawl cooperating with the second ratchet wheel are arranged on one side of the second ratchet wheel, a second pawl conversion mechanism is arranged between the third pawl and the fourth pawl, and a second driving block is arranged on the second ratchet wheel.

7. The single-layer integral welding fixture for welding motor flat wires according to claim 1, characterized in that: An outer cover plate and an inner cover plate are arranged on the base, and handles are arranged on both sides of the base.

8. The single-layer integral welding fixture for welding motor flat wires according to claim 1, characterized in that: The first positioning groove and the second positioning groove are respectively provided with an inner positioning protrusion and an outer positioning protrusion. The first positioning groove and the second positioning groove of the tool cage disc are staggered.

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